Manual actuation of PTO-based chuck

ABSTRACT

In a power driver having a chuck coupled to a drive train, an arrangement (to manually impart rotation to the drive train) includes: a housing; and a coupling mounted at least partially in the housing and connected to the drive train, the coupling being accessible though the housing, and the coupling being manually actuatable to apply a torque upon the drive train.

PRIORITY STATEMENT

This application claims the priority of U.S. Patent provisionalApplication No. 60/672,499, filed on Apr. 19, 2005, the disclosure ofwhich is incorporated herein in its entirety by reference.

Commonly-assigned, copending provisional Application, “TOOL CHUCK WITHPOWER TAKE OFF FEATURE,” United States Provisional Patent Application,Att'y Docket No. 0275L-000980/US was filed Sep. 16, 2005 with the USPTOand has been allotted Ser. No. 11/227,200, and is hereafter referred toas “the '200 application.” Commonly-assigned, copending provisionalApplication, “TOOL CHUCK WITH POWER TAKE OFF AND DEAD SPINDLE FEATURES,”was filed Apr. 19, 2005 with the USPTO and has been allotted Ser. No.60/672,503, and is hereafter referred to as the “the '503 application.”The entirety of each of the '200 and '503 applications also is herebyincorporated by reference.

BACKGROUND

Drill/driver devices include a chuck. A power take off (PTO)mechanism-type of chuck, e.g., as taught by the '200 application and/orthe '503 application, is a chuck for which the power by which its jawsare opened or closed is provided by the PTO mechanism.

If a battery by which a motor of the drill/driver device is unavailableor too depleted to adequately source power to the motor, then theBackground Art PTO mechanism-powered chuck may be unable to be openedif, e.g., an accessory remains clamped in the chuck.

In addition, there can be a circumstance in which the chuck issubstantially enshrouded by the housing of the drill/driver. In thatcircumstance, a user is prevented from grasping the chuck. Consequently,the chuck cannot be opened manually as it cannot be grasped and rotatedagainst the rotational friction provided by the non-energized motor.

SUMMARY

An embodiment of the present invention provides (in a power driverhaving a chuck coupled to a drive train) an arrangement to manuallyimpart rotation to the drive train. Such an arrangement can include: ahousing; and a coupling mounted at least partially in the housing andconnected to the drive train, the coupling being accessible though thehousing, and the coupling being manually actuatable to apply a torqueupon the drive train.

An embodiment of the present invention provides a power driver thatincludes: a housing; an armature shaft mounted in the housing; a chuckmounted on the housing and coupled to a first end of the armature shaft;and a coupling mounted to a second end of the armature shaft, thecoupling being accessible through the housing.

An embodiment of the present invention provides a power driver having adrive train, the power driver including: a housing; and a couplingmounted on the housing for rotation about a first axis to selectivelyapply a torque upon the drive train, the first axis being angled withrespect to a rotational second axis of the power driver.

Additional features and advantages of the present invention will be morefully apparent from the following detailed description of exampleembodiments, the accompanying drawings and the associated claims.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings are intended to depict example embodiments ofthe present invention and should not be interpreted to limit the scopethereof. The accompanying drawings are not to be considered as drawn toscale unless explicitly noted. Like elements are represented by likereference numerals.

FIG. 1 is a side view of a manual actuation assembly for a PTO-basedchuck, according to an embodiment of the present invention.

FIG. 2 is a three-quarter perspective view of a drill/driver thatincorporates the manual actuation assembly for a PTO-based chuck,according to an embodiment of the present invention.

FIG. 3 is a longitudinal sectional view of another manual actuationassembly for a PTO-based chuck, according to an embodiment of thepresent invention.

FIG. 4 is a three-quarter perspective view of a drill/driver thatincorporates another manual actuation assembly for a PTO-based chuck,according to an embodiment of the present invention.

FIG. 5 is an end view (taken at section line V-V′ of FIG. 4) of thedrill/driver of FIG. 4, and another manual actuation assembly for aPTO-based chuck found therein, according to an embodiment of the presentinvention.

FIG. 6A is an end view of another manual actuation assembly for aPTO-based chuck found, according to an embodiment of the presentinvention.

FIG. 6B is a side view of the manual actuation assembly for a PTO-basedchuck of FIG. 6A.

FIG. 7 is a three-quarter perspective view of some example locations forother manual actuation assemblies for a PTO-based chuck PTO-based chuckdrive train, according to an embodiment of the present invention.

FIGS. 8A and 8B are end views of another manual actuation assembly for aPTO-based chuck at different points in the operation thereof, accordingto an embodiment of the present invention.

DETAILED DESCRIPTION OF EXAMPLE EMBODIMENTS

It will be understood that if an element or layer is referred to asbeing “on,” “against,” “connected to” or “coupled to” another element orlayer, then it can be directly on, against connected or coupled to theother element or layer, or intervening elements or layers may bepresent. In contrast, if an element is referred to as being “directlyon”, “directly connected to” or “directly coupled to” another element orlayer, then there are no intervening elements or layers present. Likenumbers refer to like elements throughout. As used herein, the term“and/or” includes any and all combinations of one or more of theassociated listed items.

Spatially relative terms, such as “beneath”, “below”, “lower”, “above”,“upper” and the like, may be used herein for ease of description todescribe one element or feature's relationship to another element(s) orfeature(s) as illustrated in the figures. It will be understood that thespatially relative terms are intended to encompass differentorientations of the device in use or operation in addition to theorientation depicted in the figures. For example, if the device in thefigures is turned over, elements described as “below” or “beneath” otherelements or features would then be oriented “above” the other elementsor features. Thus, term such as “below” can encompass both anorientation of above and below. The device may be otherwise oriented(rotated 90 degrees or at other orientations) and the spatially relativedescriptors used herein interpreted accordingly.

Although the terms first, second, etc. may be used herein to describevarious elements, components, regions, layers and/or sections, it shouldbe understood that these elements, components, regions, layers and/orsections should not be limited by these terms. These terms are used onlyto distinguish one element, component, region, layer or section fromanother region, layer or section. Thus, a first element, component,region, layer or section discussed below could be termed a secondelement, component, region, layer or section without departing from theteachings of the present invention.

The terminology used herein is for the purpose of describing particularembodiments only and is not intended to be limiting of the presentinvention. As used herein, the singular forms “a”, “an” and “the” areintended to include the plural forms as well, unless the context clearlyindicates otherwise. It will be further understood that the terms“includes” and/or “including”, when used in this specification, specifythe presence of stated features, integers, steps, operations, elements,and/or components, but do not preclude the presence or addition of oneor more other features, integers, steps, operations, elements,components, and/or groups thereof.

In some of the figures, reference numbers are reused where the samecomponent may be used in more than one drawing. After a component isinitially introduced and discussed, repetitive discussion of thecomponent is kept to a minimum for the sake of brevity. Rather, furtherdiscussion focuses upon the new context in which the component isdepicted in the additional drawing(s).

FIG. 1 is a side view of a manual actuation assembly 100 for a PTO-basedchuck (not shown), according to an embodiment of the present invention.

In FIG. 1, manual actuation assembly 100 may include: a motor 102; anarmature shaft 104 of motor 102; and a coupling 106. Armature shaft 104may be extended out of the rear of motor 102, e.g., on an opposite sideof motor 102 with respect to the PTO-based chuck (not depicted in FIG.1). Armature shaft 104 may be faceted. Coupling 106 may include acomplementarily-shaped recess 108 so that, when mounted thereon,coupling 106 is rotationally fixed to armature shaft 104. Coupling 106also may include a recess 110, e.g., configured to be hex-faceted so asto receive a standard Allen wrench (also known as hex-type wrench ofAllen key) (not shown in FIG. 1) or the like; a recess such as recess110 hereafter will be referred to as a hex recess.

Insertion of the Allen wrench into recess 110 makes it possible for theuser to apply a torque to the drive train, i.e., to rotate armatureshaft 104, via rotation of the Allen wrench. In manual actuationassembly 100, over-torque protection may be provided via a clutch (notdepicted) in the transmission (not depicted) of the drill driver.

FIG. 2 is a three-quarter perspective view of a drill/driver 200 thatincorporates manual actuation assembly 100, according to an embodimentof the present invention.

In FIG. 2, coupling 106 (and hex recess 110 therein) is disposed at therear of a housing 212 of drill/driver 200, at an end opposite to aPTO-based chuck 214. A user may insert an Allen wrench 207 into hexrecess 110 of coupling 106 in order to manually rotate armature shaft104.

FIG. 3 is a longitudinal sectional view of another manual actuationassembly 300 for a PTO-based chuck, according to an embodiment of thepresent invention.

In FIG. 3, manual actuation assembly 300 may include: a motor 302; anarmature shaft 304 of motor 302; a coupling 306; and a spur gear pair301. Armature shaft 304 may be extended out of the rear of motor 302,e.g., on an opposite side of motor 302 with respect to the PTO-basedchuck (not depicted in FIG. 3). A spur gear 309 may be rotationallyfixed to armature shaft 304.

An axle 317 may be cantilevered from motor 302 parallel to armatureshaft 304. A recess 308 at a first end of coupling 306 may receive theunsupported end of axle 317. A radially exterior surface at the firstend of coupling 306 proximal to motor 302 may be provided with a gearing303 to mesh with gearing 305 on a radially outer surface of spur gear309.

Spur gearing 303 and 305 are normally not in mesh because a spring 316pushes coupling 306 away from motor 302. Upon insertion of Allen wrench207 through an opening 318 in a housing 312 and into a hex recess 310formed at a second end of coupling 306, Allen wrench 207 can be used todisplace spur gearing 303 toward spur gearing 305 in opposition to thebias force of spring 316. Once spur gearing 303 and spur gearing 305 areengaged, Allen wrench 207 can be rotated to apply a torque indirectly toarmature shaft 104.

FIG. 4 is a three-quarter perspective view of a drill/driver 400 thatincorporates another manual actuation assembly for a PTO-based chuck,according to an embodiment of the present invention.

In FIG. 4, an aperture 418 is provided in a housing 412. A user mayinsert Allen wrench 207 through aperture 418 into a hex recess 522 (seeFIG. 5) in a coupling 406 in order to manually apply a torque to thedrive train (not shown in FIG. 4).

FIG. 5 is an end view (taken at section line V-V′ of FIG. 4) ofdrill/driver 400 that includes another manual actuation assembly 500 fora PTO-based chuck found therein, according to an embodiment of thepresent invention.

In FIG. 5, manual actuation assembly 500 for a PTO-based chuck mayinclude: a spur gear 509; worm gearing 524 on coupling 406; a leafspring 526; and a spring-foundation 528, which may include, e.g., posts528 and 530 between which leaf spring 526 is disposed.

Leaf spring 526 is disposed to force worm gearing 524 out of engagementwith spur gearing 505 during normal drill/driver use. For manualoperation, Allen wrench 207 is inserted into aperture 418 and engageshex recess 522 of coupling 406. Further insertion of Allen wrench 207bias advances worm gearing 524 into engagement with spur gearing 505.Then rotation of Allen wrench 207 may apply a torque to a component ofthe drive train 504, e.g., an armature shaft, and thus PTO-based chuck214.

Manual actuation assembly 500 may be arranged to rotate drive traincomponent 504 only in one direction to loosen PTO-based chuck 214, nottighten. The effective rotational direction of Allen wrench 207 may beembossed on housing 412. Manual actuation assembly 500 may be adapted tolimit the torque that the user can manually apply, as is discussed inmore detail below.

FIG. 6A is an end view of another manual actuation assembly 600 for aPTO-based chuck found, according to an embodiment of the presentinvention. FIG. 6B is a side view of manual actuation assembly 600.

In FIG. 6, manual actuation assembly 600 for a PTO-based chuck mayinclude: a spur gear 609 having both spur gearing 605 and worm gearing644; worm gearing 624 on coupling 606; a coil spring 640; and a recess638, in a housing 612, in which is disposed spring 640; and an O-ring633.

Coupling 606 differs from coupling 406, e.g., by including a non-gearedshaft 634 extending from worm gearing 624. Spur gear 609 may be anadaptation of a standard front motor pinion. For example, spur gear 609may be formed with the powdered metal process in order to incorporateboth spur gear geometry and worm gear geometry.

O-ring seal 633 is optionally provided to reduce, if not prevent,contaminant intrusion into an interior space of housing 612. A similartype of seal can be provided as an alternative arrangement on otherembodiments of the present invention.

Coil spring 640 is disposed to force shaft 634 upward, and thus forceworm gearing 624 out of engagement with spur gearing 605 during normaldrill/driver use. For manual operation, Allen wrench 207 is insertedinto aperture 418 and engages hex recess 622 of coupling 406. Furtherinsertion of Allen wrench 207 bias advances worm gearing 624 intoengagement with spur gearing 605. Then rotation of Allen wrench 207 mayapply a torque to a component 604 of the drive train (e.g., the armatureshaft) and thus PTO-based chuck 214.

Manual actuation assembly 600 may be arranged to drive train component604 only in one direction to loosen PTO-based chuck 214, not tighten.The effective rotational direction of Allen wrench 207 may be embossedon housing 412.

FIG. 7 is a three-quarter perspective view of some example locations forother manual actuation assemblies for a PTO-based chuck drive train 700,according to an embodiment of the present invention.

In FIG. 7, a coupling 706 is provided, where coupling 706 may besimilar, e.g., to coupling 406 or 606. Coupling 706 may be provided incooperation with a pinion 705 rearward of a motor 702. Alternatively, acoupling 706′ may be provided in cooperation with a pinion 736 forwardof motor 702 but rearward of a transmission 746. Alternatively, acoupling 706″ may be provided in cooperation with a spur gear 748internally to transmission 746. Alternatively, a coupling 706′″ may beprovided in cooperation with a spur gear 750 forward of transmission746. It is to be noted that the closer to a PTO-based chuck 714 that thecoupling resides, the greater the torque that will be required on Allenwrench 207 (not shown in FIG. 7) to loosen PTO-based chuck 714.

FIGS. 8A and 8B are end views of another manual actuation assembly 800for a PTO-based chuck at different points in the operation thereof,according to an embodiment of the present invention.

Manual actuation assembly 800 may include: a spur gear 809; a coupling806; leaf springs 858 and 862; and spring-foundations 860 and 864, whichmay include, e.g., posts 830A & 832A and 830B & 832B between which leafsprings 860 and 864 are disposed, respectively.

Coupling 806 may include: a non-geared shaft 852 having a recess 822(e.g., a hex recess) at one end; worm gearing 824 formed at the otherend of shaft 852; a non-geared shaft 834 extending from worm gearing824; and a bearing end 856 formed at the opposite end of shaft 834relative to worm gearing 824.

Leaf spring 858 is disposed to force worm gearing 824 out of engagementwith spur gearing 805 during normal drill/driver use. For manualoperation, Allen wrench 207 (not shown in FIG. 8A) is inserted intoaperture 818 and engages hex recess 822 of coupling 806. Furtherinsertion of Allen wrench 207 bias advances worm gearing 824 intoengagement with spur gearing 805. Then rotation of Allen wrench 207 mayapply a torque to drive train component 804 (e.g., armature shaft) andthus PTO-based chuck 214.

The user has inserted Allen wrench 207 and applies bias and rotation toengage spur gearing 805. Once engaged, the user applies torque to rotatedrive train component 804 and the PTO-based chuck mechanism (not shownin FIGS. 8A and 8B). Leaf spring 862 is provided to facilitateover-torque protection. As the user applies a greater and greater torqueand the PTO-based chuck does not loosen, further rotation of wormgearing 824 by the user will advance worm gearing 824, furthercompressing springs 858 and 862 while moving worm gearing 824 out ofengagement with spur gearing 805, which limits further torque that canbe applied. If worm gearing is disposed to position shown in FIG. 8B,e.g., then maintenance upon manual actuation assembly 800 and/or thePTO-based chuck may be appropriate.

Allen wrench 207 and the various corresponding hex recesses X10 may takeother configurations, e.g. a Torx driver and corresponding Torx-shapedrecess, respectively, etc.

With some embodiments of the present invention having thus beendescribed, it will be obvious that the same may be varied in many ways.Such variations are not to be regarded as a departure from the spiritand scope of the present invention, and all such modifications areintended to be included within the scope of the present invention.

1. A power driver comprising: a housing; an armature shaft mounted inthe housing; a chuck mounted on the housing and coupled to a first endof the armature shaft; and a coupling mounted to a second end of thearmature shaft, the coupling being accessible through the housing. 2.The power driver of claim 1, wherein the coupling cooperates with anexternal tool to apply a torque to the armature shaft.
 3. The powerdriver of claim 1, wherein the chuck is a power take off (PTO) actuatedtype of chuck.
 4. In a power driver having a chuck coupled to a drivetrain, an arrangement to manually impart rotation to the drive train,the arrangement comprising: a housing; and a coupling mounted at leastpartially in the housing and connected to the drive train, the couplingbeing accessible though the housing, and the coupling being manuallyactuatable to apply a torque upon the drive train.
 5. The arrangement ofclaim 4, wherein the coupling includes: first and second componentshaving respective cooperating features to achieve a rotationalconnection; and a spring mounted on the first component to bias thefirst component to be disengaged from the second component.
 6. Thearrangement of claim 4, wherein the coupling includes: a spur gear onthe drive train; an axle mounted on the housing parallel to the drivetrain; a socket, a first end of which is mounted for rotation on theaxle, a circumferential surface of the first end having gearing thatmeshes with the spur gear, and and a second end of which cooperates withan external tool to apply a torque to the drive train.
 7. Thearrangement of claim 6, wherein the coupling further includes: a springto bias the gearing on the first end of the socket to be disengaged fromthe spur gear.
 8. The arrangement of claim 4, wherein the couplingincludes: a component of the drive train having helical gearing; a wormmounted on the housing orthogonal to the drive train, gearing on theworm being meshable with the helical gearing of the component, and anend of the worm cooperating with an external tool to apply a torque tothe drive train.
 9. The arrangement of claim 8, wherein the couplingfurther includes: a spring to bias the gearing on the worm to bedisengaged from the helical gearing on the component.
 10. Thearrangement of claim 8, wherein the worm includes a non-geared shaftadjacent the worm gearing to limit a magnitude of torque that can beapplied to the drive train.
 11. The arrangement of claim 10, wherein:the drive train includes a motor having an armature shaft, and a pinionconnected to the armature shaft; and the component is the pinion. 12.The arrangement of claim 9, wherein the pinion is connected to one of aside of the motor adjacent to or opposite of a transmission.
 13. Thearrangement of claim 8, wherein: the drive train includes a transmissionhaving gears; and the component is one of the gears in the transmission.14. The arrangement of claim 8, wherein the component is one of thegears in the PTO actuated chuck.
 15. The arrangement of claim 4, furthercomprising: a gasket to make a seal where between the coupling and thehousing proximal to where the coupling is accessible though the housing.16. The arrangement of claim 4, wherein the coupling is arranged to bemanually actuatable to apply a torque upon the drive train only in adirection that loosens jaws of the PTO-actuated chuck.
 17. Thearrangement of claim 4, wherein the coupling extends proximal to anaperture in the housing.
 18. The arrangement of claim 4, wherein thechuck is a power take off (PTO) actuated type of chuck.
 19. A powerdriver having a drive train, the power driver comprising: a housing; anda coupling mounted on the housing for rotation about a first axis toselectively apply a torque upon the drive train, the first axis beingangled with respect to a rotational second axis of the power driver. 20.The power driver of clam 19, wherein the first axis is substantiallyorthogonal with respect to the second axis.
 21. The power driver ofclaim 19, further comprising: a power take off (PTO) actuated type ofchuck.